Continuous manufacture of extruded clay composition bodies



J. A. SIMPSON El AL 2,612,706 CONTINUOUS MANUFACTURE OF EXTRUDED CLAY COMPQSITION BODIES Filed Dec. 13, 1949 2, SHEETS-SHEET 1 Qct. 7, 1952 INVENTORS. UsEpI-I A. QSIMPSOIV,

CLAQK SUTHEQMA/D Oct. 7, 1952 J. A. SIMPSON ET AL 2,612,706

CONTINUOUS MANUFACTURE OF EXTRUDED CLAY COMPOSITION BODIES Filed Dec. 13, 1949 2 SHEETSSHEET 2 INVENTORS. CESEPH A. .S'IMPsON,

CLARK $0 THEQLANQ BY a;

Patented Oct. 7, 1952 UNITED STATE s PATENT" w s CONTINUOUS MANUFACTURE OF EXTRUDED CLAY COMPOSITION BODIES Joseph A. Simpson, Stockton, and Clark Sutherland, Pasadena, Calif., assignors to Pacific Clay Products, Los Angeles, Calif., a corporation of California Application December 13, 1949, Serial No. 132,694

rapidly while maintaining such objects substan-.

tially straight and free from warpage or sagging. Pipe and conduit (the latter referring to what is known as multiple-duct conduit, which gen erally is of polygonal cross section) is generally made by extruding a suitably blended clay composition, cutting the extruded form into relatively short lengths (24 in.-36 in.) ,standing these short lengths on their ends upon pallets, conveying the pallets into a drying room, then moving the partially dried forms into a drier, and eventually subjecting the dried objects to burning, in order to mature the body. In some instances, the objects are sprayed with a glaze composition before burning; in other instances they are salt-glazed during burning. During these various operations many of the extruded forms are dented or deformed. Numerous attempts have been made for many years to evolve more "efficient methods of drying and handling, but none of them have proved tobe practical. It has been impossible to produce long lengths of extruded pipe because longer lengths cannot be handled in the customary manner without breakage of the freshly formed, relatively weak body. Moreover, shrinkage and warpage contribute to the production of defective, irregular, eccentric objects which cannot be effectively used in final installations. g

The present invention is directed toward methods and means whereby long lengths of pipe and conduit may be formed by the usual extrusion presses and such long lengths of pipe and conduit handled in an efficient and effective manner. Whereas normally, two, tothree weeks are required to dry'a freshly extruded section of con-' duit (thereby reducing its water content from about 20% to -6%) the method and apparatus of the present invention permit conduit to be dried in four to five hours. Furthermore, the method and means of the present invention permit' the pipe or conduit to bemanufactured in lengths of six oreight feet without warpage or,

the production of defective or damaged pieces. As a result, pipe lines can be laid with a mini mum number of joints, and .it is well known that in sewage lines, etc., most difiiculties are encountered at the joints, since these provide points of entry for roots and constitute zones where leakage occurs. It is also; to be remembered that I 2 most of the labor spent in laying mation ofthe joints. Itis evident, therefore. that the production of long lengths of ceramic pipe is the key to economical and efiicient utilization of these materials. I I

The problems confronting the ceramic industry in the production of clay pipe and conduit are aggravated by the physical characteristics of the materials being handled. The freshly extruded pipe is fragile and at the same time heavy. During drying very material shrinkage takes place. The clay pipe, because of its weight, tends to sag and since the clay is plastic and'e'xhibits what may betermed plastic deformation, the extruded objects lose their desired shape, since the object does not recoverits original shape even when the tension or pressure applied theretois released. A plastic gliding of the clay particles composing the body distinguishes clay compositions from substantially all other compositions.

Uniformity in the finished product is essential in order to permit the pipe sections or conduit sections to be suitably connected in a line, and therefore it is essential that the product maintain the co figuration imparted thereto by the extruded die.

The present invention contemplates a mode of operation whereby the pipe or conduit is extruded horizontally directly ontoa loader provided with suitable cut-01f means, whereby the continuously extruded pipe is cut into predetermined or de-' sired length. The sectionof pipe is then immediately moved in a transverse direction (preferably over a suitable marking device) and placed upon and between a pair of rollers, the loading device operating intimed relation to the'move-- The rollers connect two spaced, continuous chains, the chains and rollersment of the rollers.

constituting an endless conveyor. The conveyor extends through a drier having side walls, a roof, an open'feed end and a discharge end. The upper lay of such conveyor extends above a pair of tracks, such tracks extending longitudinally through the drier, the'rollers resting upon the" tracks in rolling contact therewith, rotationbeing imparted to the rollers by such frictional contact to the track asthe two chains are driven through the drier.- 1

As the lengths of pipe progress from the'feed end to the discharge'end ofthe drier, they are constantly rotated, since the pipe lengths are in contact with the rotating surfaces of the rollers. Means for supplying heated gases are supplied near the discharge end of the drier, such means a pipe or conduit is concerned with the preparation and for 3 supplying heated gases through ports in the side walls of the drier, a part at least of the gases so supplied being directed into the open ends of the lengths of pipe or conduit supported on the rotating rollers. An exhaust stack is in communication withthe roof of the drier adjacent the feed end thereof so that in general the heated gases pass from a point near the discharge end of the drier toward the stack and feed end, counter to the movement of the pipe and conduit.

Pursuant to the preferred mode ofoperation;

the heated gases do not travel longitudinally of the drier, but instead, are caused to zig-zag while.

they progress from the heating" sources to the. stack. As a result, the heated air is rapidly moved through the lengths of pipe from one side to the other of the drier, thereby imparting heatto the pipe in a very effective manner, preventing localized heating and insuring uniform shrinkage of .the pipe during the drying. operation without the, production of strains .or stresses which would i normallyresult in defects, fractures, etc.

Moreover, pursuant tov the present invention, means areprovided for. regulatably controlling the amount of total air or. heated gases which are deflected in.a. direction.generally transverse to the lon itudinal axis of the drier, thereby permitting. a. regulated and. controlled, quantity of heated gases to move ,towardithestack. These means permitvery accurate control of temper atures during various stagesof drying. It is; tov be remembered that .claybodiesdo notlose their waterin a uniform manner, but instead, byreason Ofthestructure of a clay. mass and the afiinity of clay for water, the. evaporation curveor rate at which. water is lost from ,abody with uniformly rising temperature is..an .irregularfunction and not ,a;. linearfunction .of;the, temperature. Thev meansherein described therefore permit specified zones'ofthe drier: to more efiectively utiliz'etheheat,or .rapidly pass .the heated gases transversely oftherdrier, whereasin other zonesthe heated gases are; permitted to move toward the feed .end and stack in a more rapid manner.

It is .an object. of w the present invention, therefore, to disclose and provide improved means'and methods of produc ng-- long; lengthsv of ceramic pipeand conduit. I

It is'= an:0bject ,of the. invention to; disclose and providemeans for. elfectivelyv and rapidly drying pipe and conduit. without deformation, sagging or: deviation; from 1 predetermined cross-sectional formc It is also an object. of thepresent invention to prov-idemeans and methods whereby lengths of pipe-and conduit ,are'moved in a lateral direction while rotating and heated gases are repeatedly passed thereover and; therethrough in directions substantiallyparallel tolthe axes of-;suc1r pipe and cond-uit.

. Theseandlother objectslandadvantages of the, invention willbecome apparent to those skilled in the art from the following description of an exemplary-ferm of apparatusinwhich themethods; herein disclosed may-be; carried out; In order to facilitate explanation, reference will behad to the appendeddrawings, in-which Fig. 1 is a side elevation of OIlBIfOI'mJQPdI'iGI contemplatedby this invention.

Fig.; 2 is a plarrview thereof,

Fig, 3 is anenlarged side .viewgofithe feed end i andassociated devices.

Fig, 4 is an enlargedtransverse section taken;

alongtheplaneIV-JV in Fig. 1';

1110.01-drwhichsupports longitudinally extending,

'. parallel; spaced, fixed rails I and 8 (see Fig. 4).

The rollerconveyor hereinbefore mentioned extends completely through the drier; such roller conveyor. may. comprise the spaced continuous chains l0 and 10! with their upper lays above the floor 6 and their lower lays beneath said floor. The ends of the conveyor are supported upon sprockets H and [2, one of said sprockets being mounted upon a shaftdriven in any suitable manner, preferably by means of a variable speed reduction gear drive generally indicated at l3.

The chains IW-andlfl carry-spaced yokes l4 adapted to rotatablyjreceive the ends'of shafts l5 extendingfrom each'of the rollers I6; ll, [8, etc. These roll'ers rest upon and frictionally contact thetracks 1 and 8,so thatwhen the conveyorchains :0 and ID" are moved-simultaneouslythe rollers lsr'lil'are'caused to rotate by rollingcontactwith the track; 'The rear lay of the conveyor may extendbe'neath the, ,floor B andthe rollers may again be supportedup on'a trackway to prevent their injury, and ;to relieve the load on the driving'chains, as illus'trated in Fig. 4.

It.may be noted" at this time that the rollers' I6 l8 are on centers spacedbetweenabout 1:2' to 217' timesjthe diameter of. each ofsaid rollers. Forexample, rollers 4 /21in. in.outside diameter may.be on '715iin. to is in. centers andwill'adequately support clay pipefi in., 8'in., or 12in; in diameter. Obviously, the diameter; and j spacing of the rollers .can be variedjin, accordance withthe size of pipe, opconduit WhlCh lS being manufac-.

tur l appreciable variation n. dia et the pipe or. nduit ne permitt d Lwith each size d. spa in of rollers... Thero lers may be. made. of wood or. metal.. lt o ghvv metallic rolle s e pre erred;

The.,-.arrangement contemplated; by this. in-

v ntion. e iminates .ullnecessaryha dling .of. I the. a pipe, or conduit. In order} to attain this. objec-v tive,- theblended clay. from-whi h the extrusions areitobe. made. is supplied ,to la puegmill 20 or. to. tandem pug mills, by meansloflachute.or;con

veyor. 2 I the. pug. mills delivering. the moistened lay, mixturetoan extrusion, machine. of the. auger. ype '(or plunger.- pe 22.. A. deaeratin'g. deviceuor. chamber. may be ,j'internosed; between. the ,pugmill-and thenextrusion machine. The.

die through Whichthedesired .shapeis. continuously extruded vis-,,dirjecte'd horizontally and prefn erably'sliglitly above, the levelfofl the shaft-upon. whichjspliocket l2 .is, ,mounted,. The extrusion machine;'22..is adjacent.,the jfeed end. 4. offthe. drier and ,is. adapted, to. discharge the pipe or. nduit. 1112911., the loading means. 23 which. in-

elude, suitable ..sev r.ing";'or .cuttingeoff. mech r msm adapted to travel with ,the extruded. pipe r while making its out. Suchcut-off mechanisms.

are well known in'the art; 'Th'e cut-ofi'mech'ae nisnr-is' arranged so 1 that the jseveredilengtth of j pipe is' directly opposite the inletf en'df of the drier and after being-severed may; be rolled over the inclined-table 24=intoa receiving-'trough 25. Theinclined table 2'4 maybe provided with" a -marking plate having letters or symbols raised above the level of the table so that when the pipe,

as at 26 and suitable means are provided for pivoting the entire trough about an axis paralle1 to the'pipe and permit the pipe to roll from the trough upon a pair of rollers of the conveyor.

Manually or automatically actuating meansfor loading the pipe onto the conveyor may be pro-- vided. A simple mechanical arrangement'is illustrated in the drawings, wherein lugs 21 carried by chain ll] of the conveyor trip a doubleacting valve 28 adapted to supply pressure fluid to cylinder 29 for actuating piston 30 having itsend pivotally connected to the trough so asto' move it into desired position. Upon reach ng discharge position, the valve 23 is automaticallyreversed, thereby lowering th trough into position to receive another section of pipe from the loading table. It is to be understood that hydraulically operated, mechanically operated, or

electrically operated means for actuating the" trough in timed relation to the movement of the conveyor may be provided.

The freshly extruded pipe is therefore rolled upon two adjacent rollers and is supp rted thereby. As the conveyor move through the" drier, the supporting rollers Iii-18' rotat the sections of pipe, and such constant rotation appears to knead the surface of the pipe, imparting added density thereto. The pipe is prevented from sag-' ging because it is constantly rotatedandgas a result its symmetry is maintained throughout the drying operation. t

It may be noted that the loading table may be provided with finishing devices which are preferably located adjacent the ends of the receiving trough 25. The finishing device may true the ends of the freshly cut sections of pipe, eliminating burrs, and, if desired, scoring the external surface of the pipe so as to facilitate subsequent bonding with sealing composition at the joints when the pipe is laid. The truingdevices employed may involve rotating cups, discs, beveling One form of such end-forming dedevices, etc. vices is illustrated in Patent No. 2,451,713.

Adjacent feed end 4 of the drier and in communication therewith is a gas exhaust'stack 40 which may be provided with a suitable fan or fans in order to facilitate the movement of gases through the drier from the discharge end 5 in countercurrent relation to the movement of the conveyor and up the stack. Near the discharge end of the drier a plurality of means for supplying heated gases are provided in each side wall.

Although the heat may be supplied from kilns within the shield is a tubular sleeve 43 containing a motor 44 connected to a fan 45 capable of rotating within the port so as to direct a blast of gases against the ends of the pipe carried by the" conveyor, such blast being directed toward the opposite wall of the drier.. Surrounding the sleeve 43 is an annulus of pipe 46 suitably connected to a source of fuel, such annulus bearing a, plurality of burners indicated at 41 and 41".

These short flame burners heat the gases which are directed against-the pipe by the ran-t5.

It may be noted at this point that the side wall construction illustrated in the drawings is exemplary only, since various forms of construction may be employed. Expensive construction need not be used inasmuch as the maximum temperatures ordinarily encountered in a drier of this type need not exceed 250 F, near the discharge end' of the drier, while thetemperature near the feed end are only on the order of ll5-130 F.

These various heat-supplying means are illustrated diagrammatically in Figs. 1 and 2 at 50, 52,54 and 55. It is to be noted that these heatsupplyin'g means are spaced from each other and are in staggered relation with the heat-supplying means 5|, 53', 55 and 57 disposed in the opposite wall of the drier. This staggered arrangement of heat sources has been foundto be particularly efiicacious. The number of heat sources employed may vary with the character and size of the pipe or conduit being treated, but in actual practice the heat-supplying means can well o'ccupy from about 15% to 25% of the total length of the drier, the zone in which the heat sources are located being adjacent the discharge end 5.

In addition to the ports through which heat is supplied, the side walls'n'iay be provided with selective, removable inspection doors such as 58 and 59.

From the arrangement disclosed it will be evident thatheated gases are caused to pass axially through the pipe on the roller conveyor. Since the exhaust stack 49 includes suction fan means, the heated gases are caused to move toward the feed end 4,'a certain proportion of the total air thus moving through the dried being blasted in a direction virtually transverse to the drier.

It will be noted from an examination of Fig. 4 that some space exists between the side walls and the ends of the conveyor. This space permits some of the heated gases to move longitudinally of the drier toward the stack 48. Means are provided for controlling the proportion of total gases within the drier which are directed toward the opposing wall by the fan and that proportion which is permitted to move longitudinally of the drier. Such means may take the form of adjustably positionable baiiles in virtually vertical planes and in cooperation with at'least some of the fans for controlling the proportion of the total gases in the drier which are directed toward the opposing wall by the fans. Such bafiles, of which Bil is an exemplar, are preferably positioned within the space between the inner side wall surface of the drier and the conveyor. .By varying the angulation of these bafiies 60, greater or larger quantities of air movpass the fans.

charge end of the drier).

fan and blown transversely of the drier. In this manner the drier actually employs a single.- stream of air which, in generaLmoves from the discharge end to the feed end of the drier. How

ever, by reason of the side wall fans and reg ulatory bafiles the air stream is caused to zig- 'zag in'its passage toward the feed end, thereby 7?." most efiectively imparting heat -to the: objects-: on the conveyor, causing drying to take.-.-place both from the. interior and-exterior surfaces -,of such objects and rapidly and uniformly- -reduce ing thamoisture content ofthe 1 objectswithou-t development ofv strains; and-the like.

Adjacent the dischargaend of the drier the roof ;ma y slope v downwardly,. as best-i indicated. at 11.. Aheat. source in the form of a gasefired: furnace 'llis positioned. on the inclinedtportion. of the -roo-f,'the hotrga'sesrgeneratedithereby being directed longitudinally into-the. drier. Since these. hot gases would. normally .travel. through theupper portion of the. driedtoward the roof along .the. ventilating stacks vMlv and during such: passage raisethe temperatures undulyr a part; 012 this .heat, is picked up 'by'a duct 13' extendin longitudinally abovethe. roof 3, this duct being... provided with .ahot, air. intake adj acent-the fur nace 12 .(such air intake. being indicated at 74): and a discharge outlet, 15 toward the central part: or the .drier. The: .ductmay include 2,- .fall..1"6,'? adjustably positionablesbafiles T! at the intake port. .M and a deflecting vvaneor -shie1d.- l& ad-,.- jacent,the outlet port. 15. This by-passductJS and its. appurtenances. constitute a refinement-- which materially. facilitates the: controhoftemperatures withinthe drier.

.We. claim:

1. In an apparatus for drying long lengths of, freshly extruded clay, pipe and conduitcomprising: alongitudinally extending. continuous -rtypeu dryer having. side walls. and aroof, said dryer having an open reed end-and a dischargeaend;

a continuous chain conveyor extending through saiddryer, said conveyor .beingprovided. with a series of- .rotatable rolls. extending. transversely of .thedryer, saidv rolls being; in spaced-relation;

fixed track means beneath the upper laytor-said conveyor,-said.track rneans being in contact with said. rolls; means for. driving., the-.conveyor:- to. moveithe rolls in a directiontransverse to [their-,- axes from the feed end; to the discharge end of the. dryer and to simultaneously impart:rotation.

thereto by ro1ling-contact with-the. track} a0 8:; eddnto the -open:-endsof the pipe and conduit. roe I tatablya supported by the (rotating rollers ofsaid.

conveyor. Y

4. In an apparatus for drying. :long lengthsw-of...

freshly extruded clay pipe .and. conduit comprissaid-. dryensaidponveyorbeing provided with aseries of rotatable rolls extending transversely of a thedryer, saidrolls being-in. spacedrelation; fixeditrack means beneaththeupper lay of: said: conveyor, said-track. means. being in contactwi-th said rolls; means vfor drivingthe conveyor to move therolls in a direction transverse to theireaxes= from the feede'nd .to the discharge .endofthe. dryer .and .to simultaneously. impart rotation... thereto by rolling contactwith the trackiaplui-m ralityof means ineach side wall of the dryer forv supplying. heated gases thereto, saidheatrsupeplying" means being. spaced from each other: :in each side. wall; asgas. exhaust stackin communi.-. cation. with. the 1 dryeradjacent the feeduend-f. thereofiandlmeans for'repeate'dlydirecting heats. ed gases in alternatel'yoppositedirections transversely. of the conveyor. and through. pipes sup ported on'lsaid conveyor. while said-heatedgases are-progressing from. near. the. discharge end oi? the. dryer toward-the :feed endthereof. and. coun-.-, ter to the movement. of. pipe-in the.dryer,.a. por.-.-- tioniof. thereof of. the dryer adjacent thetdise. charge .end being, inclined downwardly toward the discharge. end and means for supplying .heat.-= ed air. through said inclined. section of. the root longitudinally throughthe dryer andtoward the:

plurality of means-in each side wall. of the dryer. for supplying heated. gases- -thereto,-; said-pheat1;

supplying meansbeing spaced fromveachother:

in each side-wall; a :gasexhaust-stack COmr;

stackj anda plurality of auxiliar-yJam-meansfor. repeatedly directing heated: gasesin. alter.-. nately opposite directions transversely.of. the;. conveyor and through pipes supported. on? said.

conveyor while:said heated gases arei progressing from. near the-..discharge.. end of theI-drycr .to:-.-.--

ward the reed end thereof:andxcounteretoythes movementof pipe in the dryer:

2. An. apparatus ofv the 2 character stated, in.

exhaust stack.

5. In an apparatus, forv drying-longtlengthsof... freshly extruded clay pipe andconduit comprising: a longitudinally extending continuous type dryer having side walls and. a roof, said dryer having van'open feed end and a dischargeend; a. continuous chain conveyor extending; throughsaid-dryer, said conveyor. being provided. with .a. series of rotatable'rolls' extending.transverselyofi the-dryer; said rolls beingin spacedrelation .-v fixed-track means beneath the upper lay .otsa-id. J conveyorysai'd trackzm'eansbeing incontactwith said rolls: meansifor driving the conveyor. to move-therolls' in adirection transverse. to. their axes from the feed end to. the discharge, end ofthe dryer and to' simultaneously impart? rotations thereto by'rolling'contact" with. the track; aplulrality of means in each side wallof the. dryertfor.

. p yingheate'd' gases'thereto, said heat-supply.-.

ing-meansbeing spaced'from each other in each... sidewall; a gas exh'auststack in communication. with' the -dryer-adjacent"th'e' feed end thereof and means for repeatedly directing heatedv gases. in.

v alternately opposite directions transverselymoil the-conveyor and" through pipesJsupported .on...

claim 1 including 'adjustably positionable. bafflesmeans in virtually vertical; planes and.-.ini.cde-- operable-relation with attleast somesof the1aux-;

iliary fan means for controllingthe-proportiong charge; end. for. directing; gases from said". duct:

conveyor extending longitudinally.- of. the dryer-- above said floor, and. lower lays beneathsaid-fioor;

the heat-supplying means being. ini-cooperati-ve;

relation with ports inside walls. ofhthe' dryerii;

above said fioonwhereby heated gases are.-direct-;-

said conveyorwhile saidheat'ed gases are pro.-,.- gressin'g from near'the discharge end-.of .th..dry.en toward the feed end thereof: and counter. tolthe.

movement of pipe in the dryer; a pair of.;l'o'ngi tudi'n'ally spaced ports in' the. roof of. said dryer.

and a' :by pass" duct connecting the same; Ia n-- means-in'said. duct for facilitating movement of gasesgtherethrough means ..in cooperative rela t1on.with.the port farthesttremoved from the-.dis-:-

toward. the. feedQend oftthe. dryer and adjustably?" positionable.- damping 1 means in said; duct in too e operativez relationtothatport ins-closest: pr'oidm ,ity -to. the discharge endzbfrthe'dryera 6. In an apparatus for drying long lengths of freshly extruded clay pipe and conduit, the combination of: a longitudinally extending continuone type dryer having side walls and a roof, said dryer having an open feed end and a discharge end; a continuous chain conveyor extending through said dryer, said conveyor being provided with a series of freely rotatable rolls extending transversely of the dryer; a fixed track beneath the upper lay of said conveyor in contact with said rolls; means for driving the conveyor to roll the rolls by contact with the track and simultaneously move the rolls from the feed end to the discharge end of the dryer; a gas exhaust stack in communication with the dryer adjacent the feed end thereof; a portion of the roof of the dryer adjacent the discharge end being inclined downwardly toward the discharge end and means for supplying heated air through said inclined section of the roof longitudinally through the dryer and toward the exhaust stack; a plurality of auxiliary fans and heat sources in the side walls of the dryer, said auxiliary fans and heat sources in one side wall being longitudinally displaced with respect to said auxiliary fans and heat sources in the opposite side wall, for directing heated gases in alternately opposite directions transversely of the conveyor while said heated gases are progressing from near the discharge end of the dryer toward the feed end thereof.

JOSEPH A. SIMPSON.

CLARK SUTHERLAND.

REFERENCES ,CITED The following references are of record in the file of this patent:

Lindemuth Sept. 6, 1949 

